Collagen sausage casing containing encapsulated smoke and method of making

ABSTRACT

A collagen food wrapping comprising collagen extruded into a film. The collagen contains a smoke component which is encapsulated with an encapsulating material which will release the smoke component during curing or cooking and prior to consumption thereof. The invention further includes a collagen slurry containing an encapsulated liquid smoke component and a method for manufacturing a wrapped food product by extruding the slurry onto a surface of the food product to form such a film.

BACKGROUND OF THE INVENTION

This invention relates to food casings, wrappings, and slurry madeprimarily from collagen protein.

Smoking of food products such as meats, e.g. sausages and cheeses,isoften desirable in order to impart smoke flavor and color into the foodproduct. Unfortunately, such smoking processes have certaindisadvantages. In particular, smoke houses require a large amount ofpollution control in order to avoid contaminating the environment.

Consequently, liquid smokes have been developed which contain absorbedsmoke components which can be incorporated onto or into meat products.This still has disadvantages in that careful control of added liquidsmoke is required. Liquid smokes tend to be corrosive and, if notapplied properly, cause inconsistent flavor and color. Typically, liquidsmoke is applied to the surface of food products either by showering,atomizing or spraying, all being relatively inefficient, i.e., moreliquid smoke is lost than is applied. A less common, but not rare,method of utilizing liquid smoke is to blend a measured amount of liquidsmoke directly into food products. This method, however, tends to causeartificially harsh smoke flavors and fails to impart a typical smokecolor to the surface of the food product.

Collagen sausage casings and films are made by extruding a collagenpaste or slurry either in the form of a tube or sheet. The tubes orsheets are subsequently used as a mold to form the sausage by fillingthe tube, in the case of sausage casings, or wrapping the food productin the collagen film prior to cooking, smoking or drying. A relativelynew method of producing sausage products is to simultaneously extrudethe sausage mixture and the collagen slurry with the slurry essentiallyforming the casing on the surface of the sausage mixture. Thiscombination is subsequently treated to cross-link the collagen fiberswithin the collagen slurry causing the formed casing to have adequateintegrity to act as a mold. Liquid smoke is sometimes used as across-linking agent. It is important that the collagen not be subjectedto the cross-linking agent prior to the co-extrusion process and thatthe cross-linking agent be added in the proper strength and quantity.Subsequent to co-extrusion and initial cross-linking, these sausages areoften drenched with liquid smoke to impart flavor, color and to furthercross-link the collagen skin. This drenching process has many of thesame disadvantages as those encountered in the traditional methods ofsausage production.

Subsequently, the co-extruded sausages are cooked by heating to internaltemperatures, generally in the range of 152 to 160 degrees Fahrenheit.

In the area of collagen food wrappings, such as edible collagen sausagecasings and collagen slurry, it would, therefore, be desirable toincorporate smoke flavorants and/or colorants directly into the slurryin order to avoid later smoking of contained meat product in a smokehouse or by wasteful spraying or drenching with liquid smoke. Aspreviously discussed, this has generally not been possible due todegradation effects of smoke flavorants and colorants upon collagen. Inparticular, direct exposure of collagen slurry to liquid smoke causesthe slurry to cross-link prematurely thus inhibiting formation of thefood casing by extrusion into a tube which is to later be stuffed withfood product or by direct extrusion onto the surface of a food product.

BRIEF DESCRIPTION OF THE INVENTION

The invention comprises a collagen food wrapping such as a sausagecasing comprising collagen extruded into a film which in a sausagecasing is of essentially cylindrical shape. The collagen contains asmoke component which is encapsulated with an encapsulating materialwhich will release the smoke component prior to being consumed. Theinvention further comprises a collagen slurry containing an encapsulatedliquid smoke component and a method for manufacturing a wrapped foodproduct by extruding such a slurry upon a surface of the food product toform such a film.

DETAILED DESCRIPTION OF THE INVENTION

The smoke component is preferably a smoke flavorant, colorant or bothderived from liquid smoke. The component may be either liquid or solid.

The food wrapping is a film or fiber reinforced sheet which may be inany shape encompassing contained food material. The food casing may be aflat film into which food is wrapped or it may be tubular, usuallyhaving an essentially cylindrical cross section. The casing may beextruded into such a shape prior to stuffing with food product or may bea film extruded directly upon a contained food product. "Essentiallycylindrical", as used herein means that the casing, when stuffed with aflowable foodstuff, has a central cross section which is round or variesfrom round such that the central cross section has diameters which varyin length by less than 15% from each other.

The encapsulating material is an ingestible substance which will form asolid protective shell around the smoke component but which will releasethe smoke component prior to ingestion. "Ingestion" as used in thiscontext, means that the component is swallowed. The encapsulatingmaterial is usually a lipid, i.e. a water insoluble, oil solublesubstance. Such lipids are intended to include oil soluble fatty acids,fatty acid esters, and waxes. The encapsulating material is solid atroom temperature and liquid at 100 degrees C so that the smoke componentis protected at room temperature but will be released at elevatedtemperatures encountered during curing or cooking.

In manufacturing the food wrapping of the invention, the encapsulatedsmoke component may be blended with collagen slurry to form the slurryof the invention which can be extruded to form a sheet or an empty tubeor to form a tubular film around a shaped foodstuff, e.g. as describedin U.S. Pat. No. 5,271,948, incorporated herein by reference.

EXAMPLE

A quantity of collagen slurry produced by the normal manufacturingprocess e.g., as described in U.S. Pat. No. 5,271,948, is placed in ajacketed planetary mixer. This type of mixer has two agitators that notonly rotate on their axes (rotational path) but also are mechanicallyarranged so that their axes also rotate about the center of the mixer(planetary path).

The agitators are flat and have a rectangular shape and sufficientthickness to mix without being distorted by the compound being mixed.Further, a rectangular hole is provided in the center of the agitatingblade leaving a ribbon-like perimeter to form the finished agitator.This type of construction allows the compound being mixed to pass aroundand through the individual agitator blades. Also, the agitators aretimed to be 90 degrees out of phase with one another axially so as tomaximize mixing in both the rotational path as well as the planetarypath.

After transfer of the collagen slurry to the mixer, the cooling jacketof the mixer vessel is activated with a chill water flow. Encapsulatedsmoke flavoring is added to the slurry and the mixing commenced. Theencapsulated smoke flavoring is a natural smoke flavor that has beenencapsulated in a lipid. The coating required for this invention shoulddesirably, but not essentially, have a melt point of 140-145 degrees F.The encapsulated smoke flavoring product used in the present example isa fine powder obtained from M-Cap Technologies International ofWilmington, Delaware. Other companies produce this type ofmicroencapsulated smoke flavoring, e.g., Balchem Corporation, SlateHill, N.Y.

The temperature and flow of the chill water is controlled to maintain aslurry temperature of approximately 40 degrees F. Also, the speed of themixing is controlled at a slow enough speed so as not to generate heatfrom work added and not have localized hot spots caused by shear at theedges of the agitators which could break down the encapsulating shell aswell as degrade the collagen.

The actual time of mixing should be minimal yet produce a gooddispersion of the encapsulated smoke flavoring. This time interval is afunction of batch size, mixer size and power input. In the presentexample, the time was not the controlled variable. Temperature anddispersion were instead the deciding factors. The dispersion wassubjectively determined by sight when the mixer was opened for atemperature check. When a uniform tan color was obtained, the mix wasconsidered done.

The amount of smoke encapsulant used in the trial was 15% based onslurry weight. A considerably higher concentration could be used as theencapsulated smoke flavor is a very fine powder that appears to mix withthe slurry. It is apparent that sufficient smoke flavoring to meet meatpackers requirements can be obtained for either the co-extrusionapplication or the addition to meat emulsion.

The slurry containing the encapsulated smoke (loaded slurry) was storedin a refrigerator for about two weeks with no apparent degradation.Heating of the loaded slurry after mixing showed a substantial increasein smoke odor. This indicated that the lipid "shell" had meltedreleasing the smoky odor. The heat was applied by flowing air at 170degrees F.

What is claimed is:
 1. A collagen food wrapping comprising collagenextruded into a film, said collagen having dispersed therein a smokecomponent selected from the group consisting of a smoke colorant, asmoke flavorant or a mixture thereof which is encapsulated with anencapsulating material which will release the smoke component duringcuring or cooking of the collagen wrapping and prior to consumptionthereof.
 2. The food wrapping of claim 1, wherein the wrapping is a flatfilm.
 3. The food wrapping of claim 1 wherein the wrapping is a foodcasing of tubular shape.
 4. The collagen food casing of claim 3 whereinthe smoke component is a smoke flavorant derived from liquid smoke. 5.The collagen food casing of claim 3 wherein the smoke component is asmoke colorant derived from liquid smoke.
 6. The collagen food casing ofclaim 3 wherein the smoke component imparts both smoke flavor and smokecolor.
 7. The collagen food casing of claim 3, which is in the form of acollagen film extruded directly upon a contained food product.
 8. Thecollagen food casing of claim 3 wherein the encapsulating material is alipid which is solid at room temperature and liquid at 100 degrees C. 9.The collagen food casing of claim 3 wherein the encapsulating materialis a fatty acid ester.
 10. The collagen food casing of claim 3 whereinthe encapsulating material is a wax.
 11. The collagen food wrapping ofclaim 2 wherein the smoke component is a smoke flavorant derived fromliquid smoke.
 12. The collagen food wrapping of claim 2 wherein thesmoke component is a smoke colorant derived from liquid smoke.
 13. Thecollagen food wrapping of claim 2 wherein the smoke component impartsboth smoke flavor and smoke color.
 14. The collagen food wrapping ofclaim 2 wherein the encapsulating material is a lipid which is solid atroom temperature and liquid at 100 degrees C.
 15. The collagen foodwrapping of claim 2 wherein the encapsulating material is a fatty acidester.
 16. The collagen food wrapping of claim 2 wherein theencapsulating material is a wax.
 17. A food product wrapped with thewrapping of claim
 1. 18. The wrapped food product of claim 17 whereinthe collagen is a film extruded onto a surface of the food product toform the wrapping.
 19. The wrapped food product of claim 17 wherein theproduct is sausage meat wrapped with collagen film.
 20. The wrapped foodproduct of claim 19 wherein the wrapped food product is a hot dog.
 21. Amethod for manufacturing a wrapped food product which comprisesextruding a film of collagen onto a surface of a food product whereinthe collagen has dispersed therein a smoke component selected from thegroup consisting of a smoke colorant, a smoke flavorant or a mixturethereof which is encapsulated with an encapsulating material which willrelease the smoke component during curing or cooling of the wrapped foodproduct and prior to consumption thereof.
 22. The method of claim 21wherein the encapsulating material is a lipid selected from the groupconsisting of oil soluble fatty acids, fatty acid esters and waxes. 23.The method of claim 21 wherein the food product is sausage meat.